Flat panel cardboard packaging

ABSTRACT

A flat panel cardboard packaging for protecting a flat panel (FP) comprises a base part ( 2 ), first and second side walls ( 6, 10 ) extending along parallel first and second sides of the base part ( 2 ), at least a first lid part ( 14, 18 ) adapted for covering the flat panel (FP) placed on the base part ( 2 ) between the side walls ( 6 ), and at least a first cushioning part ( 24 ). The first side wall ( 6 ) is supported at a first angle (α 1 ), which is different from 0° to a plane perpendicular to the base part ( 2 ), to form a first side deformation zone. The first cushioning part ( 24 ) comprises 10 an outer gable portion ( 28 ) and an inner gable portion ( 30 ) which is arranged at a free inner distance (IS) from the outer gable portion ( 28 ), thereby forming an end deformation zone between the outer and inner gable portions ( 28, 30 ).

FIELD OF THE INVENTION

The present invention relates to a flat panel cardboard packaging for protecting a flat panel, wherein the packaging comprises a base part, first and second side walls extending along parallel first and second sides of the base part, at least a first lid part adapted for covering a flat panel placed on the base part between the side walls, at least a first side deformation zone, and at least a first cushioning part arranged along a third side of the base part.

BACKGROUND OF THE INVENTION

Home furnishing flat panels, such as decorative panels, doors, table tops, and shelves, for interior decoration often need protection during the procedures of transportation and sales of such panels. If such a panel is not properly protected during the transportation and sales process the panel may be damaged in a manner that negatively influences the visual appearance of the panel. Such negative influence on the visual appearance will reduce the economical value of the panel, leading to economical losses.

EP 0 796 796 B1 discloses a packaging having a trapezoidal cross-section and short sides that are retracted inside the outer borders of the packaging. While such a packaging may provide some protection for an object that is stored therein, there is still a substantial risk that the object is damaged if the packaging, having the object stored therein, is, for example, accidentally dropped on a floor.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a flat panel cardboard packaging which provides improved protection for a flat panel that is stored therein.

This object is achieved by means of a flat panel cardboard packaging for protecting a flat panel, wherein the packaging comprises a base part, first and second side walls extending along parallel first and second sides of the base part, at least a first lid part adapted for covering a flat panel placed on the base part between the side walls, and at least a first cushioning part arranged along a third side of the base part, said third side being perpendicular to said first and second sides, wherein the first side wall is supported at a first angle α1, which is different from 0° to a plane PV which is perpendicular to the base part, to form a first side deformation zone, wherein the first cushioning part comprises an outer gable portion, which is connected to the third side of the base part, and an inner gable portion which is arranged at a free inner distance from the outer gable portion, thereby forming an end deformation zone between the outer and inner gable portions.

An advantage of this invention is that the flat panel is protected at least at one side thereof, by the first side deformation zone, and also obtains an improved protection at its end, by the end deformation zone, as the outer and inner gable portions, arranged at a distance from each other, will provide a particularly stable end deformation zone which can resist also severe impacts.

According to one embodiment the second side wall is supported at a second angle α2, which is different from 0° to a plane PV which is perpendicular to the base part, thereby forming a second side deformation zone. An advantage of this embodiment is that the flat panel is protected at both sides thereof.

According to one embodiment the first side wall is supported at the first angle α1 by the first cushioning part. An advantage of this embodiment is that the first side wall is supported in a manner which improves the strength and integrity of the first side deformation zone.

According to one embodiment the first cushioning part comprises at least a first side edge which supports the first side wall at the first angle α1. An advantage of this embodiment is that the first side wall obtains improved side support, which further improves the strength of the first side deformation zone.

According to one embodiment the second side wall is supported at the second angle α2 by the first cushioning part. An advantage of this embodiment is that the second side wall is supported in a manner which improves the strength and integrity of the second side deformation zone.

According to one embodiment the first cushioning part comprises at least a second side edge which supports the second side wall at a second angle α2, which is different from 0°. An advantage of this embodiment is that the second side wall obtains improved side support, which further improves the strength of the second side deformation zone.

According to one embodiment the cardboard packaging further comprises a second cushioning part arranged along a fourth side of the base part, said fourth side being perpendicular to said first and second sides and being opposite to said third side. An advantage of this embodiment is that the flat panel is protected from impacts at both of its ends.

According to one embodiment said second cushioning part is a mirrored embodiment of the first cushioning part. An advantage of this embodiment is that the flat panel will obtain a similar protection at both of its ends.

According to a preferred embodiment the free inner distance IS between the inner gable portion and the outer gable portion is at least 10 mm. If the free inner distance IS is less than 10 mm the protective function of the first and/or second end deformation zone will be rather limited.

According to a preferred embodiment the free inner distance IS between the inner gable portion and the outer gable portion is maximum 100 mm. A free inner distance IS exceeding 100 mm would mean that the packaging would consume unduly large transport volumes, without substantially further increasing the protective function of the first and/or second end deformation zone.

According to one embodiment the first and/or the second end deformation zone is provided with a filling. An advantage of this embodiment is that the strength of the end deformation zone is increased. According to one embodiment, the filling comprises a paper material, for example corrugated cardboard. Paper materials are cheap, have high strength, and are suitable for recycling together with the rest of the packaging.

According to one embodiment a cross bar portion extends, in a diagonal manner, between the outer and inner gable portions in the first and/or the second end deformation zone. An advantage of this embodiment is that the end deformation zone is further reinforced by the cross-bar. Thereby, a further improved protection for the end of the flat panel is obtained.

According to one embodiment the first angle α1 is 10-60°. The first angle α1 is preferably 10° or more, more preferably 20° or more, since this provides for improved protection of the side of the flat panel. The first angle α1 is preferably not more than 60°, since an angle of more than 60° results in a very large packaging which may be less economical. More preferably, the first angle α1 is not more than 30°, as this provides for an efficient packaging with relatively low volume.

According to one embodiment the outer and inner gable portions are parallel to each other. An advantage of this embodiment is that a deformation zone of large strength is obtained.

According to one embodiment the outer gable portion is perpendicular to the bottom part. An advantage of this embodiment is that it improves the stability of the cushioning part and improves the resistance to impacts in a direction perpendicular to the bottom part.

According to one embodiment the cushioning part comprises a gable connecting portion that connects the outer and inner gable portions to each other and holds them at a free inner distance from each other. This provides for improved stability of the cushioning part. According to a preferred embodiment the gable connecting portion is parallel to the base part. This provides for further increased stability and strength of the cushioning part. According to one embodiment the gable connecting portion extends substantially parallel to the base part and a height H1 above the same. The height H1 is preferably in the range of 8 to 100 mm. Such a height H1 has been found to be suitable for many types of flat panels that need protection by a cardboard packaging.

According to one embodiment the first cushioning part comprises an inner gable supporting portion connected to the inner gable portion opposite to the gable connecting portion and adapted to extend in parallel with the base part from the inner gable portion towards the outer gable portion. An advantage of this embodiment is that the inner gable portion is securely held in its desired position. According to a preferred embodiment the inner gable supporting portion extends the entire distance from the inner gable portion to the outer gable portion. Thereby, the inner gable portion may rest, via the inner gable supporting portion, against the outer gable portion and thereby obtain further support.

According to one embodiment an end gable of the packaging has, in the area of the first cushioning part, the shape of a trapezoid without right angles. This shape provides for efficient protection of a flat panel. Preferably the first angle α1 is equal to a second angle α2 between the second side wall and the plane PV which is perpendicular to the base part. Thereby a symmetrical package is obtained, which makes storing and handling easier. Preferably, the end gable has the general shape of a truncated triangle. This shape has been found to be strong and provide a good protection for a flat panel. Preferably, the complete packaging has the shape of a gold bar or of a trapezoidal prism. These shapes form an efficient and strong packaging.

According to one embodiment the first and second side walls lean inwardly towards the base part. This embodiment provides for simple packaging of a flat panel in the packaging.

According to one embodiment the end gable of the packaging has, in the area of the first cushioning part, the shape of a parallelogram without right angles. This embodiment is, for example, useful in some applications where the two sides of the flat panel are in use of protection at different edges.

According to one embodiment the inner gable portion is fixed, directly or indirectly, to the base part by means of an adhesive device, such as glue or a tape. An advantage of this embodiment is that the inner gable portion is kept in place, which makes it easier to put a flat panel in place in the packaging. Furthermore, the adhesive may also improve the strength of the complete cushioning portion. The adhesive device could, for example, be arranged between the inner gable supporting portion and the base part, or between the inner gable portion itself and the base part.

According to one embodiment the packaging comprises corrugated cardboard, wherein flutes of the corrugated cardboard extend in a direction which is parallel to the first and second sides of the base part. An advantage of this embodiment is that the strength of the outer and inner gable portions is increased, thereby increasing the strength of the cushioning part.

According to one embodiment the first cushioning part is provided with an additional second outer gable portion that lies adjacent to the first outer gable portion, at the inside thereof. This strengthens the outer gable portion, and makes it more resistant to intrusive objects, such as knifes, and to compressive forces acting in a direction parallel to the outer gable portion. It also increases the overall strength of the cushioning part.

According to one embodiment, the first cushioning part is provided with an additional second inner gable portion that lies adjacent to the first inner gable portion, at the inside thereof. This strengthens the inner gable portion, and reduces the risk that the flat panel is exposed to damage, also in situations of heavy impact forces on the cushioning part. According to one embodiment the second inner gable portion is connected to a cross bar portion. This serves to efficiently hold the second inner gable portion in its intended position. According to one embodiment, the second inner gable portion is supported by a second inner gable supporting portion extending in parallel to the base part. This provides extra strength to the second inner gable portion, and secures that it is held in its intended position.

According to one embodiment said at least a first lid part adapted for covering a flat panel placed on the base part is connected to at least one of the first and second side walls. An advantage of this embodiment is that said at least a first lid part is efficiently held in place on the packaging.

According to a further aspect there is also provided a flat panel cardboard packaging blank adapted for forming a flat panel packaging for protecting a flat panel, wherein the blank comprises a base part, first and second side walls extending along parallel first and second sides of the base part, and at least a first cushioning part arranged along a third side of the base part, said third side being perpendicular to said first and second sides, wherein the first cushioning part is adapted to support the first side wall at a first angle α1, which is different from 0° to a plane PV which is perpendicular to the base part, to form a first side deformation zone, wherein the first cushioning part comprises an outer gable portion, which is connected to the third side of the base part, an inner gable portion, and a gable connecting portion arranged between the outer and inner gable portions and adapted to hold the outer and inner gable portions at a free inner distance from each other to form an end deformation zone between the outer and inner gable portions.

According to one embodiment, the first cushioning part comprises a first side edge forming a first angle to the first side of the base part, when the packaging blank is in its unfolded state, and this first angle is different from 0°, wherein the first side edge is adapted to support the first side wall at the first angle when the packing blank has been folded to become a flat panel cardboard packaging. An advantage of this embodiment is that the side wall obtains a particularly good support.

This flat panel cardboard packaging blank is suitable for forming a flat panel cardboard packaging that provides efficient protection on at least one side and also on at least one end of a flat panel stored therein.

According to one embodiment the flat panel cardboard packaging blank further comprises at least a first lid part adapted for covering a flat panel placed on the base part between the side walls. An advantage of this embodiment is that the complete packaging can be made from fewer pieces, since also a lid part is included in the packaging blank. Preferably, said at least a first lid part extends along at least one of the first and second side walls of the packaging blank.

Further objects and features of the present invention will be apparent from the description and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in more detail with reference to the appended drawings in which:

FIG. 1 is a plan view illustrating a packaging blank according to a first aspect of the present invention.

FIG. 2a is three-dimensional view illustrating a first step of folding a packaging from the blank of FIG. 1.

FIG. 2b is a cross-section taken along the arrows II-II of FIG. 2a and illustrates a first cushioning part.

FIG. 3 is three-dimensional view illustrating a second step of making a packaging from the blank.

FIG. 4a is three-dimensional view illustrating a third and final step of making a packaging from the blank.

FIG. 4b is a side view illustrating an end gable of the packaging.

FIG. 4c is a cross-section illustrating the protective arrangement of the packaging.

FIG. 5 is a cross-section of a cushioning part according to an alternative embodiment.

FIG. 6 is a cross-section of a cushioning part according to a further alternative embodiment.

FIG. 7 is a cross-section of a cushioning part according to a still further alternative embodiment.

FIG. 8 is a plan view and illustrates an end gable according to an alternative embodiment.

FIG. 9 is a cross-section of a cushioning part according to a still further alternative embodiment.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 illustrates a packaging blank 1 for a flat panel cardboard packaging according to a first aspect of the present invention. The packaging blank 1 comprises a base part 2, which has, in this embodiment, a rectangular shape and is connected to, along a first side 4 thereof, a first long side wall 6, and is connected to, along a second side 8 thereof, which is opposite to the first side 4, a second long side wall 10.

The first long side wall 6 is connected, along a first side 12 thereof, said first side 12 being parallel to the first side 4 of the base part 2, to a first lid part 14, and in a similar manner the second long side wall 10 is connected, along a first side 16 thereof, said first side 16 being parallel to the second side 8 of the base part 2, to a second lid part 18.

The base part 2 further comprises third and fourth sides 20, 22. The third and fourth sides 20, 22 extend along opposite ends of the base part 2 and are at right angles to the first and second sides 4, 8. A first cushioning part 24 is connected to the third side 20 of the base part 2, and a second cushioning part 26 is connected to the fourth side 22 of the base part 2. The first and second cushioning parts 24, 26 are, in this embodiment, designed according to similar principles, wherein the second cushioning part 26 is mirrored compared to the first cushioning part 24, as illustrated in FIG. 1, and therefore only the first cushioning part 24 is described in detail hereinafter.

The first cushioning part 24 comprises an outer gable portion 28, which is connected to the third side 20 of the base part 2, and an inner gable portion 30. The outer and inner gable portions 28, 30 are connected to each other by a gable connecting portion 32. The gable connecting portion 32 is adapted to hold the outer and inner gable portions 28, 30 at a free inner distance from each other and is adapted to lie against the first and second lid parts 14, 18, as will be described hereinafter.

The outer gable portion 28 is provided with first and second opposite side edges 34, 36 that in this embodiment are arranged in a non-parallel manner. The first side edge 34 forms a first angle α1 to the first side 4 of the base part 2, when the packaging blank 1 is in its unfolded state, as illustrated in FIG. 1, and this first angle α1 is different from 0°. Preferably, the first angle α1 is in the range of 10-60°. The second side edge 36 forms a second angle α2 to the second side 8 of the base part 2, and this second angle α2 is different from 0°, and is preferably in the same range as the first angle α1. Preferably the first and second angles α1, α2 have the same value, e.g. 25°, and wherein the side edges 34, 36 point towards a common first apex AX1.

The inner gable portion 30 is provided with first and second opposite side edges 38, 40 that preferably are arranged in a non-parallel manner. The first side edge 38 forms a third angle α3 to the first side 4 of the base part 2, and this third angle α3 is different from 0°. Preferably, the third angle α3 is in the range of 10-60°, and preferably the third angle α3 has the same value as the first angle α1. The second side edge 40 forms a fourth angle α4 to the second side 8 of the base part 2, and this fourth angle α4 is different from 0°, and is preferably in the same range as the third angle α3, and preferably the fourth angle α4 has the same value as the second angle α2. Preferably the third and fourth angles α3, α4 have the same value, e.g. 25°, and wherein the side edges 38, 40 point towards a common second apex AX2, located opposite to the first apex AX1.

A first outer gable folding line 41 is arranged between the base part 2 and the outer gable portion 28. The first outer gable folding line 41 coincides with the third side 20 of the base part 2. A second outer gable folding line 42 is arranged between the outer gable portion 28 and the gable connecting portion 32, and a first inner gable folding line 44 is arranged between the gable connecting portion 32 and the inner gable portion 30.

In the embodiment of FIG. 1, the first cushioning part 24 further comprises an optional inner gable supporting portion 46 which is connected to the inner gable portion 30, opposite to that end of the inner gable portion 30 where the gable connecting portion 32 is connected, wherein a second inner gable folding line 47 is arranged between the inner gable portion 30 and the inner gable supporting portion 46. The inner gable supporting portion 46 is arranged to lie against the base part 2 and to enhance the stability of the inner gable portion 30, as will be described hereinafter.

Furthermore, in the embodiment of FIG. 1, the first cushioning part 24 comprises an optional cross bar portion 48 which is connected to the inner gable supporting portion 46, wherein a cross bar folding line 50 is arranged between the inner gable supporting portion 46 and the cross bar portion 48. At the opposite end of the cross bar portion 48 a distal edge 52 is arranged. The distal edge 52, which is parallel to the third side 20 of the base part 2, marks the end of the cushioning part 24. The cross bar portion 48 is arranged to extend, in a diagonal manner, from a position adjacent to the first outer gable folding line 41 and towards the first inner gable folding line 44 and to reinforce the stability of the cushioning part 24 according to the principles of a cross bar, as will be described hereinafter.

The packaging blank 1 is preferably made from cardboard or corrugated cardboard. The packaging blank 1 has a length axis LA, which extends through the base part 2 and the cushioning parts 24, 26, as shown in FIG. 1. Hence, the length axis LA is parallel to the sides 4, 8 of the base part 2. If corrugated cardboard is used as material for the packaging blank 1, then the flutes of the corrugated cardboard layer of the corrugated cardboard should preferably extend along the length axis LA to obtain maximum mechanical strength of the cushioning parts 24, 26 after they have been folded into their intended shape, i.e., the flute direction in the perspective of FIG. 1 is vertically upwards.

FIG. 2a is three-dimensional view illustrating how the cushioning parts 24, 26 have been formed by folding them. Hence, the base part 2 is, in this state, provided with two cushioning parts 24, 26 arranged in opposite ends thereof. A flat panel, in the illustration of FIG. 2a schematically depicted as a home furnishing flat panel FP, having the general shape of a rectangular parallelepiped, may be placed on the base part 2, between the two cushioning parts 24, 26. By “flat panel” is, as used herein, referred to a sheet-shaped object, such as a door, hatch, decorative panel, shelf, table surface, floor panel, etc., that has a substantially uniform thickness, and wherein the thickness of the flat panel is smaller than the length and the width of the panel.

FIG. 2b is a cross-section through the first cushioning part 24, as seen along the arrows II-II of FIG. 2a . In the embodiment shown the cardboard packaging blank is made from a corrugated cardboard material which comprises an outer face cardboard layer OCL, an inner face cardboard layer ICL and additionally a central corrugated cardboard layer CCL arranged between the outer and inner face cardboard layers OCL, ICL.

As illustrated in FIG. 2b , a first folding has been made at the first outer gable folding line 41 to make the outer gable portion 28 extend essentially vertically upwards from the base part 2. A second folding has been made at the second outer gable folding line 42 to make the gable connecting portion 32 extend in the direction of the second cushioning part 26, and substantially perpendicular to the outer gable portion 28. Thereby, the gable connecting portion 32 extends substantially parallel to the base part 2, and a height H1 above the same. The height H1 depends on the thickness of the panel FP to be stored in the packaging, and may typically be in the range of 8 to 100 mm.

A third folding has been made at the first inner gable folding line 44 to make the inner gable portion 30 extend essentially vertically downwards from the gable connecting portion 32 and towards the base part 2. Thereby, the outer gable portion 28 and the inner gable portion 30 are both substantially perpendicular to the base part 2. Furthermore, the outer gable portion 28 and the inner gable portion 30 are parallel to each other, and there is a free inner distance IS between them. The size of the free inner distance IS depends on how much protection that is needed for the panel FP. Typically, the free inner distance IS is in the range of 10-100 mm.

Since, in a preferred embodiment, all of the first, second, third and fourth angles α1, α2, α3, and α4 have the same value, the first side edge 34 of the outer gable portion 28 will, as illustrated in FIG. 2a , be parallel to the first side edge 38 (hidden in FIG. 2a ) of the inner gable portion 30, and the second side edge 36 of the outer gable portion 28 will be parallel to the second side edge 40 of the inner gable portion 30.

Returning to FIG. 2b , a fourth folding has been made at the second inner gable folding line 47 to make the inner gable supporting portion 46 extend in a direction away from the second cushioning part 26, and substantially perpendicular to the inner gable portion 30. The inner gable supporting portion 46 extends in parallel with the base part 2 and is in contact therewith. According to one embodiment the inner gable supporting portion 46 could be fixed to the base part 2 by means of fastening arrangement 54, which, for example, could involve an adhesive device, such as a double sided tape or glue. By fixing the inner gable supporting portion 46 to the base part 2 the integrity and stability of the cushioning portion 24 is improved.

A fifth folding has been made at the cross bar folding line 50 to make the cross bar portion 48 extend, in a diagonal manner, from a position adjacent to the first outer gable folding line 41 to a position adjacent to the first inner gable folding line 44 to thereby form a cross bar. Thereby, a first end 56 of the cross bar portion 48 will be received in a corner formed between the base part 2 and the outer gable portion 28, and the distal edge 52 of the cross bar portion 48 will be received in a corner formed between the gable connecting portion 32 and the inner gable portion 30. The cross-bar portion 48 further enhances the strength of the first cushioning part 24.

FIG. 3 illustrates a further step in making a packaging from the packaging blank of FIG. 1. In this step the first long side wall 6 is folded up to become supported by the parallel first side edges 34 and 38 of the outer and inner gable portions 28, 30 of the respective first and second cushioning parts 24, 26, and the second long side wall 10 is folded up to become supported by the parallel second side edges 36 and 40 of the outer and inner gable portions 28, 30 of the respective first and second cushioning parts 24, 26. Since the angles α1, α2, α3, and α4 are different from 0°, as illustrated and described hereinbefore with reference to FIG. 1, the long side walls 6, 10 will lean slightly inwards towards the base part 2. The gable connecting portion 32 forms, in addition to holding the outer and inner gable portions 28, 30 at a desired distance from each other, a platform onto which the lid parts 14, 18 may rest, as will be shown hereinafter.

FIG. 4a illustrates a final step in forming a flat panel cardboard packaging 60 from the packaging blank 1 illustrated in FIG. 1 to cover the panel FP. In this final step, the first and second lid parts 14, 18 are folded onto the respective cushioning part 24, 26 and rest against their respective gable connecting portion 32. Optionally, a piece of tape 62 could be applied to the lid parts 14, 18 to fix them to each other and to the respective outer gable portion 28. Optionally, the lid parts 14, 18 could be glued to the respective gable connecting portions 32, shown in FIG. 2b . The packaging 60 is now ready for transportation and sales activities. The packaging 60 of FIG. 4a has the shape of a trapezoidal prism, but may, in alternative embodiments, have other shapes, such as the shape of a gold bar.

FIG. 4b is a side view illustrating an end gable 64 of the packaging 60 of FIG. 4a . As can be seen from FIG. 4b , the end gable 64 has the shape of a trapezoid without right angles, and the trapezoid shape is symmetrical around a vertical centre line. The shape of the end gable 64 is, hence, similar to the cross-section of a truncated triangle. The first side edges 34 and 38, of which the latter is hidden in the perspective of FIG. 4b , will have the respective above-mentioned first and third angles α1, α3 to a plane PV which is perpendicular to the base part 2, wherein the first and third angles α1, α3 are equal to each other and both are different from 0° to the plane PV. Thereby the long side wall 6, which is supported by the side edges 34, 38, will not be perpendicular to the base part 2, but will have the first angle α1, which is different from 0°, to the plane PV which is perpendicular to the base part 2. Similarly, the second side edges 36 and 40, of which the latter is hidden in the perspective of FIG. 4b , will have the respective above-mentioned second and fourth angles α2, α4 to a plane PV which is perpendicular to the base part 2, wherein the second and fourth angles α2, α4 are equal to each other, and also equal to the first and third angles α1, α3, and are both different from 0° to the plane PV. Thereby the long side wall 10, which is supported by the side edges 36, 40 will not be perpendicular to the base part 2, but will have the second angle α2, which is different from 0°, to the plane PV which is perpendicular to the base part 2. As the long side walls 6, 10 are supported by the side edges 34, 36, 38, 40 of the inner and outer gable portions 28, 30, of which the latter is hidden in FIG. 4b , and since the side edges 34, 36, 38, 40 are not perpendicular to the base part 2 but lean inwardly toward it, a first side deformation zone 66 is formed between the first long side wall 6 and the panel FP, and a second side deformation zone 68 is formed between the panel FP and the second long side wall 10.

In FIG. 4b the flutes FT formed by the central corrugated cardboard layer CCL are partly shown, in the end gable 64. As already noted hereinbefore with reference to FIG. 1, the flutes FT preferably extend in a direction along the length axis LA of the packaging blank 1.

FIG. 4c is a cross-section of the first cushioning part 24 and of a part of the packaging 60, as seen in a perspective similar to that of the cross-section of FIG. 2b . The packaging 60 is, in this embodiment, held together by the tape 62. As described hereinabove with reference to FIG. 2b the outer and inner gable portions 28, 30 of the first cushioning part 24 have a free inner distance IS between them. Thereby a third deformation zone being an end deformation zone 70 is formed between the gable portions 28, 30. The gable connecting portion 32 and the inner gable supporting portion 46 will support the outer and inner gable portions 28, 30 and hold them at the desired free inner distance IS.

The end deformation zone 70 will protect the flat panel FP also upon large impact forces that may arise when, for example, the packaging 60 is dropped, with its cushioning part 24 first, on a floor. As can be seen, the outer and inner gable portions 28, 30 are both perpendicular to the bottom part 2. This increases the stability of the cushioning part 24, and improves its stability to impacts. In a preferred embodiment the packaging 60 is so designed that the panel FP will lie against the inner gable portion 30 and provide further support to it. Additionally, the cross bar portion 48 will further support the outer and inner gable portions 28, 30 and thereby further reinforce the end deformation zone 70.

FIG. 5 illustrates a cushioning part 124 according to an alternative embodiment, and seen in a cross-section similar to that of FIG. 2b . The cushioning part 124 comprises outer gable portion 128, inner gable portion 130, gable connecting portion 132 and inner gable supporting portion 146 that are all similar to the corresponding parts of the cushioning part 24. However, in the embodiment of FIG. 5 there is no cross bar portion. The strength of the cushioning part 124 is therefore slightly lower than that of the cushioning part 24, but this may be sufficient for packaging intended for panels of lower weight. In a further alternative embodiment, the inner gable supporting portion 146 extends only a portion of the free inner distance between the inner gable portion 130 and the outer gable portion 128.

In accordance with an alternative embodiment, an end deformation zone 170 formed between the outer and inner gables 128, 130 may be at least partly filled with a filling 172 to increase the physical strength of the end deformation zone 170. This filling 172 could, for example, be paper, pieces of cardboard, foamed plastic, etc. In the embodiment illustrated in FIG. 5, the filling 172 comprises several strips 174 of corrugated cardboard, wherein the strips 174 have been glued together to form the filling 172.

FIG. 6 illustrates a cushioning part 224 according to a further alternative embodiment, and seen in a cross-section similar to that of FIG. 2b . The cushioning part 224 comprises outer gable portion 228, inner gable portion 230, and gable connecting portion 232 similar to the corresponding parts of the cushioning part 24. However, in the embodiment of FIG. 6 there is no inner gable supporting portion 46. A cross bar portion 248 extends directly from a lower end of the inner gable portion 230 to a corner formed between the outer gable portion 228 and the gable connecting portion 232. In the cushioning part 224 there is relatively limited space for an optional fastening arrangement 254, which, for example, could involve an adhesive device, such as tape or glue, which may be applied between the base part 202 and a corner formed between the inner gable portion 230 and the cross bar portion 248. However, in some embodiments also a rather weak fastening arrangement 254 may be sufficient, and in other embodiments it would also be possible to dispense of fastening arrangements, in particular in cases where a panel FP lies adjacent to the inner gable portion 230 and keeps the cushioning part 224 in place.

FIG. 7 illustrates a cushioning part 324 according to a further alternative embodiment. The cushioning part 324 comprises outer gable portion 328, inner gable portion 330, gable connecting portion 332, and inner gable supporting portion 346 similar to the corresponding parts of the cushioning part 24. Additionally, the cushioning part 324 is provided with an additional second outer gable portion 329. The additional second outer gable portion 329 lies against the first outer gable portion 328, at the inside thereof, and supports the same. Thereby, a double layered outer gable arrangement is obtained, wherein a cushioning part 324 with extra strength is obtained. According to a further option, a cross bar portion 348 may be arranged in the cushioning part 324, and this cross bar portion 348 is connected to the second outer gable portion 329 and extends from a corner formed between the first outer gable portion 328 and the gable connecting portion 332 to a corner formed between the inner gable portion 330 and the inner gable supporting portion 346. Thereby, a further reinforcement of the cushioning part 324 is obtained.

FIG. 8 is a plane view illustrating a packaging 460 having an end gable 464 according to an alternative embodiment. The perspective of FIG. 8 is similar to that of FIG. 4b and similar parts have been given similar reference numerals. In this embodiment the first and second side edges 434 and 436 of the outer gable portion 428 and of an inner gable portion (not shown in the perspective of FIG. 8) have angles α1, α2 that are each different from 0° to planes PV that are perpendicular to a base part 402, but in contrast to the embodiment illustrated in FIG. 4b , the first and second side edges 434 and 436 of the outer gable portion 428 are parallel to each other, and similarly, the first and second side edges of the inner gable portion (not shown) are also parallel to each other. The end gable 464 thereby has the shape of a parallelogram without right angles. As long side walls 406, 410 are supported by the side edges 434, 436 of the inner and outer gable portions 428, of which the latter is hidden in FIG. 8, a first deformation zone 466 will be formed between the first long side wall 406 and panel FP, and a second deformation zone 468 will be formed between panel FP and the second long side wall 410. It will be appreciated that the cross-section of a cushioning part 424 of the packaging 460 could, for example, be arranged according to the principles of any of the embodiments illustrated in FIGS. 2b, 4c , 5, 6, 7 and 9. As can be seen from FIG. 8 the two deformation zones 466, 468 are not symmetrical around the panel FP. This can be an advantage in situations when the flat panel is in itself not symmetrical, and/or in situations when the panel FP at one side, e.g. the left side in FIG. 8, needs most protection at its lower edge, and on the other side, e.g. the right side in FIG. 8, needs most protection at its upper edge.

In the embodiment of FIG. 8 a single lid part 414 is illustrated and this lid part 414 is connected to the second long side wall 410. The lid part 414 comprises, at an opposite end thereof, a connecting portion 415 which overlaps with the first long side wall 406 and which is fixed to the first long side wall 406 by means of, for example, a string of glue 454. This principle of arranging a single lid part 414 could be applied also to the embodiment illustrated in FIGS. 1 to 4 c. Furthermore, the solution with first and second lid parts 14, 18 illustrated in FIGS. 1 to 4 c could also be applied to the embodiment illustrated in FIG. 8.

FIG. 9 illustrates a cushioning part 524 according to a further alternative embodiment. The cushioning part 524 comprises outer gable portion 528, a first inner gable portion 530, gable connecting portion 532, a first inner gable supporting portion 546, and cross bar portion 548 that are similar to the corresponding parts of the cushioning part 24 described hereinbefore. Additionally, the cushioning part 524 is provided with an additional second inner gable portion 531. The additional second inner gable portion 531 is connected to the cross bar portion 548, at an end thereof which is opposite to that end at which the cross bar portion 548 is connected to the first inner gable supporting portion 546, and lies against the first inner gable portion 530, at the inside thereof, and supports the same. Thereby, a double layered inner gable arrangement is obtained, comprising the first inner gable portion 530 and the second inner gable portion 531, wherein the cushioning part 524 obtains extra strength, in particular in that region, i.e. at the inner gables 530, 531, where the cushioning part 524 is adapted to be in contact with a flat panel FP stored inside the packaging.

Optionally, the cushioning part 524 may additionally comprise an additional second inner gable supporting portion 547. The additional second inner gable supporting portion 547 is connected to the second inner gable portion 531, at an end thereof which is opposite to that end at which the second inner gable portion 531 is connected to the cross bar portion 548, and lies against the first inner gable supporting portion 546, parallel to the base part 502, at the inside thereof. Thereby, the stability of the first and second inner gable portions 530, 531 is enhanced.

It will be appreciated that numerous variants of the above described embodiments are possible within the scope of the appended claims.

Hereinbefore it has been described that the packaging blank is made from corrugated cardboard. It will be appreciated that the packaging blank could also be made from other materials, including cardboard having no corrugated layer.

Hereinbefore it has been indicated that the end deformation zone 70 formed between the outer and inner gables 28, 30 may be in principle empty, with the exception for an optional cross bar 48. It will be appreciated that it is also possible to further improve the strength of the end deformation zone 70, if necessary, by adding some kind of filling to be placed inside the deformation zone 70, as illustrated as an example in FIG. 5. Such filling could, for example, be foamed plastic, paper, pieces of cardboard, etc.

Hereinbefore it has been described that the first side wall 6 is supported by the side edges 34, 38 of the cushioning part 24. In an alternative embodiment the first side wall 6 could be supported by just one of these side edges 34, 38, for example by the first side edge 34, while the other side edge 38 is not in contact with the first side wall 6. A further possibility is that the first side wall 6 is not supported by any of the side edges at all, but is supported by another portion of the cushioning part 24, for example the gable connecting portion 32. Similarly, the second side wall 10 could be supported by both side edges 36, 40 of the cushioning part 24, by just one of these side edges 36, 40, for example by the first side edge 36, while the other side edge 40 is not in contact with the second side wall 10, or could be supported by the gable connecting portion 32. Still further, one or both of the side walls 6, 10 could be supported in another way as alternative or in combination to being supported by the cushioning part 24. For example, one or both side walls 6, 10 could be supported at its intended angle by the panel FP.

Hereinbefore it has been described that the lid parts 14, 18, 414 are integrated parts of the packaging blank 1, as shown in FIG. 1. It will be appreciated that according to alternative embodiments, one or more lid parts could also be separate pieces that are mounted to the side walls 6, 10 by means of, for example, glue, tape or similar. Hence, the lid parts could be integrated pieces of the packaging blank, or could be added at a later stage in the production of the flat panel cardboard packaging.

To summarize, a flat panel cardboard packaging for protecting a flat panel (FP) comprises a base part (2), first and second side walls (6, 10) extending along parallel first and second sides of the base part (2), at least a first lid portion (14, 18) adapted for covering the flat panel (FP) placed on the base part (2) between the side walls (6, 10), and at least a first cushioning part (24). The first side wall (6) is supported at a first angle (α1), which is different from 0°, to a plane perpendicular to the base part (2), to form a first side deformation zone. The first cushioning part (24) comprises an outer gable portion (28) and an inner gable portion (30) which is arranged at a free inner distance (IS) from the outer gable portion (28), thereby forming an end deformation zone between the outer and inner gable portions (28, 30). 

1. A flat panel cardboard packaging for protecting a flat panel (FP), wherein the packaging comprises a base part, first and second side walls extending along parallel first and second sides of the base part, at least a first lid part adapted for covering a flat panel (FP) placed on the base part between the side walls, and at least a first cushioning part arranged along a third side of the base part, said third side being perpendicular to said first and second sides, wherein the first side wall is supported at a first angle (α1), which is different from 0° to a plane (PV) which is perpendicular to the base part, to form a first side deformation zone, wherein the first cushioning part comprises an outer gable portion, which is connected to the third side of the base part, and an inner gable portion which is arranged at a free inner distance (IS) from the outer gable portion, thereby forming an end deformation zone between the outer and inner gable portions.
 2. A flat panel cardboard packaging according to claim 1, wherein the second side wall is supported at a second angle (α2), which is different from 0° to a plane PV which is perpendicular to the base part, thereby forming a second side deformation zone.
 3. A flat panel cardboard packaging according to claim 1, wherein the first side wall is supported at the first angle (α1) by the first cushioning part, preferably the first side wall is supported at the first angle (α1) by at least a first side edge of the first cushioning part, and wherein the second side wall is preferably supported at a second angle (α2), which is different from 0°, by the first cushioning part, preferably the second side wall is supported at the second angle (α2) by at least a second side edge of the first cushioning part.
 4. A flat panel cardboard packaging according to claim 1, further comprising a second cushioning part arranged along a fourth side of the base part, said fourth side being perpendicular to said first and second sides and being opposite to said third side, preferably said second cushioning part being a mirrored embodiment of the first cushioning part.
 5. A flat panel cardboard packaging according to claim 1, wherein a cross bar portion extends, in a diagonal manner, between the outer and inner gable portions through the end deformation zone.
 6. A flat panel cardboard packaging according to claim 1, wherein the first angle (α1) is 10-60°.
 7. A flat panel cardboard packaging according to claim 1, wherein the outer and inner gable portions are parallel to each other.
 8. A flat panel cardboard packaging according to claim 1, wherein the first cushioning part comprises a gable connecting portion that connects the outer and inner gable portions to each other and holds them at the free inner distance (IS) from each other, preferably the gable connecting portion is parallel to the base part.
 9. A flat panel cardboard packaging according to claim 8, wherein the first cushioning part comprises an inner gable supporting portion connected to the inner gable portion opposite to the gable connecting portion and adapted to extend in parallel with the base part from the inner gable portion towards the outer gable portion.
 10. A flat panel cardboard packaging according to claim 1, wherein an end gable of the packaging has, in the area of the first cushioning part, the shape of a trapezoid without right angles, preferably the first angle (α1) is equal to a second angle (α2) between the second side wall and the plane (PV) which is perpendicular to the base part, more preferably the end gable has the general shape of a truncated triangle, still more preferably the packaging has the shape of a trapezoidal prism.
 11. A flat panel cardboard packaging according to claim 10, wherein the first and second side walls lean inwardly towards the base part.
 12. A flat panel cardboard packaging according to claim 1, wherein an end gable of the packaging has, in the area of the first cushioning part, the shape of a parallelogram without right angles.
 13. A flat panel cardboard packaging according to claim 1, wherein the inner gable portion is fixed, directly or indirectly, to the base part by means of an adhesive device, such as glue or a tape.
 14. A flat panel cardboard packaging according to claim 1, wherein the packaging comprises corrugated cardboard, wherein flutes (FT) of the corrugated cardboard preferably extend in a direction which is parallel to the first and second sides of the base part.
 15. A flat panel cardboard packaging according to claim 1, wherein the first cushioning part is provided with an additional second outer gable portion that lies adjacent to the first outer gable portion, at the inside thereof.
 16. A flat panel cardboard packaging according to claim 1, wherein the first cushioning part is provided with an additional second inner gable portion that lies adjacent to the first inner gable portion, at the inside thereof.
 17. A flat panel cardboard packaging according to claim 1, wherein said at least a first lid part adapted for covering a flat panel (FP) placed on the base part is connected to at least one of the first and second side walls.
 18. A flat panel cardboard packaging blank adapted for forming a flat panel packaging for protecting a flat panel (FP), wherein the blank comprises a base part, first and second side walls extending along parallel first and second sides of the base part, and at least a first cushioning part arranged along a third side of the base part, said third side being perpendicular to said first and second sides, wherein the first cushioning part is adapted to support the first side wall at a first angle (α1), which is different from 0° to a plane (PV) which is perpendicular to the base part, to form a first side deformation zone, wherein the first cushioning part comprises an outer gable portion, which is connected to the third side of the base part, an inner gable portion, and a gable connecting portion arranged between the outer and inner gable portions and adapted to hold the outer and inner gable portions at a free inner distance (IS) from each other to form an end deformation zone between the outer and inner gable portions.
 19. A flat panel cardboard packaging blank according to claim 18, wherein the packaging blank comprises at least a first lid part adapted for covering a flat panel (FP) placed on the base part, wherein the at least a first lid part is connected to at least one of the first and second side walls.
 20. A flat panel cardboard packaging blank according to claim 18, wherein the first cushioning part comprises a first side edge forming a first angle (α1) to the first side of the base part, when the packaging blank is in its unfolded state, and this first angle (α1) is different from 0°, wherein the first side edge is adapted to support the first side wall at the first angle (α1) when the packing blank has been folded to become a flat panel cardboard packaging. 